Aplicação da metodologia DMAIC para melhorias no processo de pintura em uma empresa de implementos rodoviários

Abstract

With the great development of production techniques and the increase in competitiveness in all market segments, companies are seeking to turn their actions and objectives towards the quality of their products and processes to meet their clients' requirements. One of the methodologies that have this focus is the Six Sigma, understood as a strategic and statistical tool for reducing waste and failures and increasing reliability, thus generating profits for the organizations. This paper presents a case study developed in a road implements company with the objective of installing improvements in the chassis painting sector in order to make the process able to meet the requirements and reduce the number of reworks. For the development of the study the DMAIC (Define, Measure, Analyze, Improve, and Control) method was used, understood as a structured cycle of planned actions and specific tools for each phase, capable of obtaining failure correction and positive results in the projects in which it is implemented. In the initial stage of the cycle, it was defined as the quality variable to be analyzed the layer of dry paint after the painting process and with the help of control charts it was measured how the parameters were before the application of the project. It was stablished that the process was out of statistical control due to having high variability in the averages of the data, the focus of the study was the reduce of the standard deviation of the data, to obtain the six sigma level from the implementation of improvements that directly attack the causes, such as changing the raw material (paint) used, definition of operational standard, use of measurement tools for the employees and implementation of specific inspection sheet for painting. After applying the action plans, there was an improvement in the results, with a reduction in the standard deviation from 6.4 to 2.3, less variability of the averages, an increase in the capability indices: Cp from 0.523 to 1.266, Cpk from 0.519 to 1.224, Pp from 0.281 to 0.684 and Ppk from 0.280 to 0.661, therefore, strong indications of the achievement of the defined objectives. The work contributed to the possible use of DMAIC in other projects in different sectors of the company.